Field- and System Simulation

Transcription

1 Product Titelmasterformat Development durch through Klicken Combined bearbeiten Field- and System Simulation 1

2 Actuators are systems Typical applications: Magnetic switch Valve Relay Example for general systems: thermal, fluid, elastic, electro-magnetic, acoustic Challenge: Fatigue Chatter, electric arc Switch time Why now? Competition situation Quality management Software is ready to use Produktbilder Quelle: wikipedia 2

3 Mechanical and magnetic system 3

4 State model (SPMWRITE) Linear mechanical subsystem from Modal analysis is converted to a state model inside Mechanical The motion is described through eigenmodes: frequency as criterion Definition of terminals for the connection between parts in the system, e.g. contact Prepared commands object ExportStateSpaceMatrices.mac (!) 4

5 Magnetic lookup-table (ECE) 2D or 3D magnetic static problem is solved inside Maxwell. The lookup-table is created with Optimetrix: Torque and flux linkage as function of armature angle and coil current General force-deflection for all terminal pairs 5

6 Workflow in ANSYS Workbench Maxwell: Lookup-table, ECE General nonlinear force-deflection curve for armature angle and current as state variables. Mechanical Modal: State space model from SPMWRITE Modal analysis with terminals Simplorer: System simulation Solves the system equations for reduced order models, 0D elements, also co-simulation ECE SPMWRITE 6

7 Simplorer Modeling Techniques System simulation Electric Magnetic Mechanical Hydraulic Thermal Acoustic H Simplorer all domains can be coupled Co-Simulation Block Diagrams State Graphs Digital/VHDL Reduced Models PROCESS (CLK,PST,CLR) BEGIN IF (PST = '0') THEN state <= '1'; ELSIF (CLR = '0') THEN state <= '0'; ENDIF; 7

8 Simplorer Modeling Techniques System simulation Electric Magnetic Mechanical Hydraulic Thermal Acoustic H Simplorer all domains can be coupled t=0 Co-Simulation Co-Simulation controller 3D Model Reduced Models t=t+1 3D Model (10 6 eq.) Reduced Model (10 2 eq.) Reduced model t=0 controller Reduced Model t=t+1 8

9 F F Simplorer Modeling Techniques System simulation Electric Magnetic Mechanical Hydraulic Thermal Acoustic H Simplorer all domains can be coupled Co-Simulation Vx Given velocity ANSYS Simulation Displacement response (tooling location) F + S VY F Co-Simulation ANSYS Vy + - PID GAIN F + S in2 + S out2 + S Desired displacement response KP= KI= Input ANSYS Output ANSYS KD=1000 in1 out1 + S Vx PID F S KP= KI= KD=0 + S 9

10 Simplorer Modeling Techniques System simulation Electric Magnetic Mechanical Hydraulic Thermal Acoustic H Simplorer all domains can be coupled Reduced model M & x&+ Ex& + Kx = f MOR x & = Ax + f n = 40Mio. DOFs m=10 DOFs F_TRB1 F Force_ux Disp1_ux 0 0 F_TRB2 F Why? Fast & Accurate Transient FEA 1h Transient ROM 4 sec How? Modal, MOR, LTI, ECE, DoE 10

11 Simplorer Modeling Techniques System simulation Electric Magnetic Mechanical Hydraulic Thermal Acoustic H Simplorer all domains can be coupled Reduced model Modal Reduction by SPMWRITE M & x&+ Ex& + Kx = f MOR x & = Ax + f n = 40Mio. DOFs m=10 DOFs Structural 11

12 Simplorer Modeling Techniques System simulation Electric Magnetic Mechanical Hydraulic Thermal Acoustic H Simplorer all domains can be coupled Reduced model MOR4ANSYS M & x&+ Ex& + Kx = f MOR x & = Ax + f n = 40Mio. DOFs m=10 DOFs Thermal

13 Simplorer Modeling Techniques System simulation Electric Magnetic Mechanical Hydraulic Thermal Acoustic H Simplorer all domains can be coupled Reduced model LTI (transfer function based) CFD solution FLUENT Icepak M & x&+ Ex& + Kx = f MOR x & = Ax + f Input system Output Reduced Model n = 40Mio. DOFs m=10 DOFs Conjugate Heat Transfer 13

14 Simplorer Modeling Techniques System simulation Electric Magnetic Mechanical Hydraulic Thermal Acoustic H Simplorer all domains can be coupled Reduced model ECE Equivalent Cirquit Element M & x&+ Ex& + Kx = f MOR x & = Ax + f n = 40Mio. DOFs m=10 DOFs electromagnetic Electric Drive with Maxwell 14

15 Simplorer Modeling Techniques System simulation Electric Magnetic Mechanical Hydraulic Thermal Acoustic H Simplorer all domains can be coupled Reduced model DoE inputs CAE or experiments outputs M & x&+ Ex& + Kx = f MOR x & = Ax + f n = 40Mio. DOFs m=10 DOFs 15

16 Subsystem in Simplorer Magnetic system with current source Lookup-table: torque and flux from current and angle Electric and rotational terminals Armature-spring-subsystem State model in modal basis Translational and rotational terminals Pre-stressed armature spring through contact in Simplorer Electric arc model: switch with z-diode Electric arc voltage = voltage of z-diode Energy measurement of electric arc 16

17 Total system Physical domains: electric, rotational, translational Transient simulation 17

18 Result: coil current and voltage Coil voltage rectangular impulse: Relay mono-stable Coil current shows armature bouncing Electric arcing current occurs with reopening conducting switch after current over inductive load had started 18

19 Live Example 19

20 Parameter study Study of system character as function of parameter Contact distance Pretension Coil resistance -1,85-1,90-1,95 ΦKipp / Linear Regression of tclose COP 90% tclose / s Result Clear failure indicators pretension, voltage Arc power reduced by 61% Power consumtionreduced by 19% -2,00-2,05-2,10-2,15 failed designs successfuldesigns USp / V 20

21 Parameter study Study of system character as function of parameter Contact distance Pretension Coil resistance Voltage at actuator Position of contact Parameter set 1 Parameter set 2 optimizedparameter set Result Clear failure indicators pretension, voltage Arc power tclose1 tcloseopt Arc power reduced by 61% Power consumtion reduced by 19% 21

22 Summary Field simulation provides the effective reduced order model for system simulation The different field simulations can be provided from the experts, who are responsible for the specific part of the system Parameter study of system properties is very effective Export of complete system behavior is possible to: customers or other departments The virtual product can consider the full set of system interactions Acknowledgment Ralf Hoffmann, PHOENIX CONTACT Electronics GmbH 22

23 Titelmasterformat Simulation makes durch a lot of Klicken things bearbeiten possible Together we can make the most of it. 23